CASTING

• Casting- It is a process in which molten liquid

metal will we allow to solidify in a pre define
mould cavity after solidification required
shape of object can be produced.
• Pattern : Replica of final object.(Wood, Metal
alloys, plastics- thermocole, pvc)
• Types of pattern:
• Single/solid piece pattern :-used for simple
shape of the pattern.
• Split/Two piece pattern:- if the object to be
produced in complex shape and size this
pattern can be used with number of split
pieces. Such that they can be removed from
cope & drag separately.
• Loose piece pattern:- if the pattern having
internal projection or undercuts loose piece
pattern can be used.
• Gated pattern:- it is use for simple shape of
object in mass production. Number of patterns
along with gating element will produce a single
pattern known as gated pattern
• Match plate pattern:- produce complex shape of
object in mass production. Number of pattern
can be split along pattern line and they will be
added on both side of match plate.
• Sweep pattern:- To produce complex shape of
3d objects, 2d plane pattern will be rotated on
the surface of the mould. It is used for the axis
symmetric object like cone, large size bell,
cylinder.
• Pattern allowance
1. Shrinkage/Contraction Allowance:-
• Liquid metal is allowed to solidify inside the
cavity, there is a chance of contraction or
shrinkage of the material. When the liquid
metal is cooled from pouring to freezing
temperature it is liquid shrinkage. During
phase transformation shrinkage of metal is
called solidification shrinkage. When solid
casting is cooled from freezing to room
temperature it is called solid shrinkage.
2. Draft allowance:- for easy removal of the
pattern and to minimize continuous contact
between pattern and mould surface this
allowance is provide.
3. Machining Allowance:- casting object are not
having smooth surface finish to get better
surface finish machining is required.
4. Shake/Rapid allowance:- moulding sand will stick
to the surface of the pattern during ramming, for
easy removal of pattern clearance is produced
between the pattern and mould surface by shaking
the pattern.
5. Distortion allowance:- depending on shape and
size of the casting due to difference in shrinkage
value there is a possibility of distortion of the
casting. To overcome this allowance is provided on
the pattern opposite to the direction of distortion.
Sand Casting
• Flask:- a moulding flask is one which hold the
sand mould intact. Depending upon the
position of the flask in the mould structure, it
is refered by various name such as cope, drag,
cheek. It is generally made up of wood for
temporary and metal for long term.
• Core:- it is used for making hollow cavity in
casting.
• Pouring basin:- a small funnel shaped cavity at
the top of the mould in to which the molten
metal is poured.
• Sprue:- the passage through which the molten
metal from the pouring basin reaches the
mould cavity.
• Runner:- the passage ways in the parting
plane through which molten metal flow is
regulated before they reach the mould cavity.
• Gate:- the actual entry point through which
molten metal enters the mould cavity.
• Chaplets:- it is used to support core inside the
mould cavity to take core of its own weight.
• Chills:- these are metallic objects which are
placed in the mould to increase the cooling
rate of casting to provide uniform or desired
cooling rate.
• Riser:- It is the reservoir of molten metal
provided in the casting so that hot metal can
flow back in to the mould cavity when there is
a reduction in volume of metal due to
solidification.
 Properties of moulding sand
• Refractoriness:- it is the ability of the moulding
sand to withstand high temperature of molten
metal without fusion.
• Green strength:- The moulding sand that contains
moisture is termed as green sand.
• Dry strength:- when the molten metal is poured
into a mould the sand around the cavity is quickly
converted into dry sand as the moisture in the
sand immediately evaporates due to the heat in
the molten metal.
• Hot strength:- it is the strength of the sand that is
required to hold the shape of the mould cavity
after all the moisture is eliminted.
• Types of sand
• Green sand:- if the sand contains 2-6% of
moisture than the sand is called green sand.
• Dry sand:- it is the moisture available in the
moulding sand evaporates causes of high
temperature of molten metal than it is dry sand.
• Composition of moulding sand
Silica sand – 70-85%
Clay - 10-20%
Water - 3-6%
Additives - 1-6%
 SHELL CASTING

• Shell casting:- Moulding material is in contact

with heated pattern activating the bonding
property of phenolic resin moulding sand will
stick to the surface of the pattern in form of
shell.
• Thickness of the shell depends on the contact
time between pattern and moulding material.
• Moulding material: fine grain silica,
thermosetting plastics (Phenolic resin)
• To produce better surface of the object compare
to sand moulding this technique can be used.
• Pattern is used by producing metalic material it
will be heated up to 250 degree Celsius.
• Moulding material is in contact with heated
pattern by activating the bonding property of
phenolic resin.
• Moulding sand will be sticking to the surface of
the pattern in the form of shell
• Thickness of the shell will depend on contact time
between pattern and moulding material also
known as dwell time.
• After getting required thickness of the shell
pattern, it can be separated from the mould box
& producing number of the shell.
• It is difficult to produce very complex shape of
the object.
• Application:
• Cylinder block, I C Engine, Rocker arm, valve
plates of refrigerator.
SHELL CASTING
 INVESTMENT CASTING

• Investment casting:- the investment casting

process also called the lost wax process. The
pattern made up of wax/plastics such as
polystyrene by moulding or rapid prototyping
technique. This sequence involve in
investment casting are shown in figure
INVESTMENT CASTING
• Application: Gas turbine blade, jet engine
parts, medical implants, surgical instrument,
gold ornaments.